SITCOM QUALITY CONTROL MANUAL(draft version)

Introduction This quality control manual, hereafter known as QC Manual, was created as a reference document to ensure that all vendors adhere to Sitcom quality standard, and Sitcom quality control process. QC Manual is used as instruction document for Sitcom QC staffSitcom Agent and Sitcom vendor to refer during production and quality control process. 2.1 Inline inspection The Inline inspection is used to monitor the quality of the product through the production rough mill, machining, assembling stages and finishing stages until the beginning of the packing stage. 2.1.1 Preparation documents for inline inspection To conduct one inline inspection, Sitcom QC need to have and study the below

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850 42ND Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E: sitcom@sitcomfurniture.net

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Not Approved

Passed Failed

Signed off Master Sample by

PD or QCM

Passed

Sitcom QCM to take photos of

MS, document it and sent to sitcom PD, KSDIV1 for approval and record

Vendor conduct in-house quality test, drop test with Sitcom QC/Agent

Sitcom QC/Agent to take pictures, document then send to Sitcom PD for approval

Vendor make sample

Checked by Sitcom QC or

PD

Not Passed

Not Approved

Vendor Improve

product or packing

Not Passed

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QCM : Quality Control Manager

1.2 Sample Development Flow For Resourced Items

For old items that resourced to new vendor the sample development flow will be as below

Vendor send samples for

MTL test if required by

Sitcom

Checked by Sitcom PD

Not Approved

Passed Failed

Signed off Master Sample by PD

or QCM

Sitcom QCM to take photos of MS, document it and sent to sitcom PD, KSDIV1 for approval and record

Vendor conduct in-house quality test, drop test with Sitcom QC/Agent

Sitcom QC/Agent to take pictures, document then send to Sitcom PD for approval

Approved

Checked

by Sitcom

PD Passed

Old product is sent to vendor from Sitcom

Vendor make sample

Vendor Improve

product or packing

Not Passed

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1.3 Color Panel Development Process Flow

Vendor needs to submit 12 pcs of color panel size 10”x10”for Sitcom PD to approve Approved color panel will be filled information below on the back of panel

Code of color (Track from PSA form)

Number of color panel signed

After signing Approved color panels, 6 pcs of color panel will be returned to vendor Sitcom will keep 6 pcs, 4 pcs for Sitcom local office/Agent for QC’s inspection using and 2 for Sitcom

PD Vendor will use approved color panel during the finish process During the production process, vendor needs to check product before and after each steps of finishing to assure all required steps and coating application are followed in manufacturing process

Vendor prepare 12 pcs 10”x10”

for Sitcom review

Sitcom PD or QC to review (color, sheen, adhesion, Pencil hardness)

Sitcom to sign Approved color panel 6 pcs will be kept by vendor,

4 pcs kept by Sitcom local office/Agent, 2 pcs kept by PD

Vendor and Sitcom QC use color panel to check product during

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CHAPTER 2 INSPECTION PROCEDURE 2.1 Inline inspection

The In-line inspection is used to monitor the quality of the product through the production rough mill, machining, assembling stages and finishing stages until the beginning of the packing stage

2.1.1 Preparation documents for inline inspection

To conduct one inline inspection, Sitcom QC need to have and study the below

Master sample signed

Approval color panel

Document of master sample signed with photos

Document of approval inhouse packing drop test during sample development stage

Document of approval inhouse quality test

Sitcom PSA sheet

MTL packing test if product is required

MTL quality test if product is required

Defect Classification List document

During inspection time in the factory QC inspector can be required to update actual production status, any quality problems or any jeopardy that affect to shipment point for Sitcom office staff

The frequency of the In-line inspection will depend upon the type of product being produced, the production quality as perceived, the vendor’s past performance and the order quantity

2.1.3 Procedure

The In-line inspection includes checking the raw material’s quality, construction, measurement, color, labels, hardware, tags, carton printing, workmanship, with special

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attention to finish, paint, sheen, durability and instructions If QC found any problems or discrepancies they must bring to the attention of the vendor management so that action can be taken to correct the problem or discrepancies A inspection report should be completed every time an In-line inspection is performed at a factory All information are recorded in the inspection report must be explained in verbal by Sitcom QC to factory representatives All problems, defects and discrepancies that need to be improved, corrected must be noted in the report After reviewing, the factory management should sign the report indicating full understanding and agreement to rectify the discrepancies as discussed If the factory management disagrees with the findings, they can comment the points they do not agree with However, the factory management must sign the report

In the case of any serious issues found by QC, The Sitcom QC Manager must be informed immediately to support If one serious issue found that jeopardise to shipment point QC inspector should also inform Sitcom Sourcing/ Merchandise manager

During inline inspection Sitcom QC should walk along the production line to review the production (or components) for the following:

a) Material Quality and colors

with the focus as below

At the rough mill ( Cutting, sawing, planning, glueing…) stage: Verify what is material used, quality of material, MC for Key components

At the machining (drilling, shaping, routering…) stage: measure dimensions, MC, the accuracy of angle, square… for the key components

Assembling stage: Assembly 3 products QC should ask factory to use correct hardware if available Verify step by step with Assembly Instruction, check construction is stable after test or not, check operation components can work smoothly, MC conduct interchange test with old item if it is a resourced item

Sanding stage: Check smooth of surface, focus to sanding marks, glue marks, all edges should be sanded 1.5mm radius or follow the note on Master Sample if specified

Finishing stage: verify color, sheen against with approval color panel Sitcom QC should compare all components in the product for matching for example the legs should be compare with frame, top, drawer… for color match and sheen Quantity

of inspection should be at least 3 pcs for each key components

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Preparation before packing: verify carton layout, PO sticker, hardware bag/blister bag, hardware sticker, desicant bag, law label, packing material and way of packing

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Summaried table for inline inspection

2.1.4 In-line inspection report distribution

Copy of the Inline Inspection Reports must be sent to factory right after vendor represantative

signed Full inline inspection report with attached photos is expected to fullfill by Sitcom QC

within latest one working day after inspection date and to send to Sitcom QC manager for

review Sitcom office staff will send QC inline inspection report to Sitcom US

<=12% Prefer within 8-12%

3 pcs for each key

MC must be <=12% Prefer within 8-12%

3 pcs for each key

components Assembling stage Verify step by step with

Assembly Instruction

Construction

Operation components, hardware

to get correct hardware if available

Sanding stage A, B surfaces, joints,

grooves…

Must be smooth No sanding marks, glue marks accepted All edges should be sanded 1.5mm radius or follow the note on Master Sample

3 pcs for each key

components

Finishing stage Matching color, sheen Approved color panel

All components in the product should mtach color and gloss for example the legs should be compare with frame, top, drawer… for color match and sheen

At least 3 pcs for each key components

Preparation before

packing

Carton layout, PO sticker, hardware bag/blister bag, hardware sticker, desicant bag, law label

Packing material and way

of packing

Approved carton layout

Sitcom standard for hardware bag, sticker, desicant, law label

MTL packing test or inhouse drop test report

At least 3 pcs

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2.2.1 Preparation documents for final inspection

To conduct one Final Inspection, Sitcom QC need to have and study the below

Master sample signed Vendor need to bring master sample to inspection area for Sitcom QC to verify

Approval color panel

Document of master sample signed with photos

Document of approval inhouse packing drop test during sample development stage

Document of approval inhouse quality test

Sitcom PSA sheet

MTL packing test if product is required

MTL quality test if product is required

Defect Classification List document

Measuring tape

Drawing if possible

Camera

2.2.2 Inspection Schedule

To schedule and arrange Final-line inspections properly and effectively, the QC Manager must

be kept well informed of the progress of the mass-production The sitcom office staff need to work with vendor on the approximate completion dates for the manufacturing of the P.O and pass to the QC Manager to plan the inspection schedule Any changes in production schedules the office staff should inform QC Manager so that QA inspection schedules can be adjusted accordingly

During inspection time in the factory QC inspector can be required to update actual production status, any quality problems or any jeopardy that affect to shipment point for Sitcom office staff

Each separate shipment and SKU will require a Final Inspection conducted by a Sitcom/Agent

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2.2.3.3 Assembly Test

This test is only applicable to Knock Down (KD) items The test-sampling plan should be at least 3 pcs Generally, for any lot size, 3 samples are selected, all of which must pass the test in order for the shipment to be passed The inspector should assemble the furniture unit in accordance with the Assembly Instruction sheet enclosed with the package, using the tools in hardaware bag to assemble

The following will result in automatic failure: - - The knock down components cannot be assembled/do not fit together - Missing parts, hardware, screws, specified special assembly tools, etc - The assembled item cannot function as intended, e.g drawers cannot move, doors cannot be opened, table/chair not level, etc - Mistakes in the assembly instructions, improper use of language/missing language (if multi-lingual) If the test result is ‘failed’, the shipment cannot be released

2.2.3.4 Drop Test

Only the first shipment is required drop test In the case packing material is suspicious to have discrepancies that tools to check that is not available in factory then Sitcom QC can require inhouse drop test to verify packing

Drop test quantity is done for one carton only but any fails, the shipment cannot be released vendor needs to improve packing to pass drop test before shipment

2.2.3.5 Workmanship Check

The inspector will use some kinds of sampling plans below for workmanship check

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one product before putting into carton

First shipment at new vendors

Products have quality issue in the past shipments

Replacement orders DUP (During

Packing line)

level

At least 70% quantity of product randomly checked

by Sitcom QC before putting into carton

Normal first shipment at old vendor

When Sitcom QC available at the packing time it prefers to apply this for repeat orders than AQL level AQL 4.0 L1 (

MIL-STD-105E)

Use AQL table below to determine the quantity of sample The selected samples should be representative of the total shipment

At least 80% of the shipment lot has been packed and the balance cleared from the production lines

AQL 4.0 level 1 MIL-STD 105E table

Level 1 (AQL 4.0)

Lot Size (shipment size)

Sample size (Inspected qty) Accept Reject

The parts listed below is also listed out in the final inspection report should be followed for

every inspection so that no part of the operation is overlooked

a) Material defects

b) Construction defects

c) Finishing defects

d) Color, sheen check: compare with approved color panel and checking color match between

parts in one product and in one lot

e) Upholstery defects

f) Handling defects

g) Hardware defects

h) Functional defects

2.2.3.6 Identify the Defects

During the quality check, the position of all major and minor defects should be marked using a

adhesive red arrow sticker The QA Inspector should also make a note of the type of defect

found, to be used when compiling the inspection report at the end of the evaluation process

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The items with major defects should be put to one side Once inspection of the sample lot has been completed, the total number of defective units should be recorded in the appropriate box provided on the Final Inspection report form This figure will determine whether the goods can

be accepted or rejected against the inspection plan being used

2.2.3.7 Final inspection report distribution

Copy of the Final Inspection reports must be sent to factory right after vendor represantative signed Full Final Inspection report with attached photos is expected to fullfill by Sitcom QC within latest one working day after inspection date and to send to Sitcom QC manager for review Sitcom office staff will send QC Final Inspection report to Sitcom US

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CHAPTER 3

QC INSPECTOR’S RESPONSIBILITY 3.1 Escalation Of Problems In a Direct Sitcom Factory

Below chart will instruct Sitcom QC which quality problem level should raised to which level

on Sitcom side and factory side

3.2 Escalation Of Problems In An Indirect Sitcom Factory

If Sitcom uses an agent, Sitcom QC should advise all problems noted to the Agent’s QC personnel and to the Agent’s QC supervisor Problems noted will be communicated by the Agent QC supervisor to the Factory personnel Sitcom personnel should not discuss quality problems directly with the Factory personnel If the Agent QC are not present, the Agent

QC supervisor should be called

The process for quality disagreements is as follows:

Sitcom QC addresses with Agent QC, if Agent QC disagrees, address to Agent QC Supervisor

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To regularly report any irregularities and monitor any shipments being held pending the correction of discrepancies, ensuring that the Sitcom or sitcom’s client quality expectations are met

Sitcom QC address with

Sitcom QC Manager

Sitcom QC Manager address with Agent QC /supervisor Manager

Sitcom QC Manager address with PD Manager

Agreed

Agreed Disagreed

Disagreed

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3.3.3 Duties and Responsibilities

To personally visually examine adequate product sample lots prior to shipment to ensure that Sitcom specifications and standards have been adhered to, and to ensure that the general appearance of the product is acceptable

To ensure that product is correctly sorted, labeled and packaged, and that the cartons are properly marked, exhibiting the correct destination, department and article number

To prepare inspection reports for all product inspected, for both in-line and final inspections, and submit the reports to the QC Manager

To submit inspection records for in-line and final inspections to the QC Manager on time

To conduct inhouse quality test and inhouse drop test and record the test when required

To prepare monthly and quarterly reports as directed by the QC Manager

To maintain QC file, product doc, approval color panel… in good condition, and easy for using

To check upon the implementation of corrective action plan and report to QC manager

Liaise with Sitcom Sourcing/Merchandise as required on production status and report them immediately any potential shipment delays

Completed and submit weekly as required the actual production status at each incharged vendor

To provide the QC Manager with recommendations for improvement

3.3.4 Knowledge and Skills Required

Have at least three to five years’ related experience in furniture Technical qualifications are desirable

Know general product quality standards, statistical sampling, packaging, labeling and carton marking requirements

English language capability is expected but not a must

Effective communication skills and have the ability to work and interact with other

Be able to work independently with minimum supervision

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3.3.5 QC Peformance

QC inspectors will be evaluated quarterly which include an assessment of

Completeness of documentation on time

Attendance: Faithfulness in coming in to work daily and conforming to scheduled work hours

Familiarity with Sitcom procedures

QC record from PC comments, claim value

Reliability - The extent to which the employee can be depended upon to be available for work, do it properly, and complete it on time The degree to which the employee is reliable, trustworthy and persistent

Judgment - The extent to which the employee makes sound decisions Ability to base decisions on fact rather than emotion

Factory cooperation and internal cooperation: Willingness to work harmoniously with others in getting a job done Readiness to respond positively to instructions and procedures

Quantity of Work - Work output of the employee

Initiative and Creativity - The ability to plan work and to go ahead with a task without being told every detail, and the ability to make constructive suggestions

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Sanding before finishing

Finishing Master color panel #: Signed by: Date:

Verify pre-packing

Overall comments and disposition

(carton lay out, law label, care

instruction, AI, hardware, hardware

bag/ blister-pack, PO sticker)

(cutting, planning, gluing/pressing)

Randomly check on 5 components

Measure MC for main components

(MC should be 8-12 for indoor

furniture)

Measure dimension, position of

drilling holes,…Randomly check 5 pcs

of main components.

Assemble 3 products: check stability?

Moving components operate

smoothly? No gap at joints? Easily

assembly? dimension is correct? MC

check and write down MC range

Smooth? No oversanding? Edge

should be with 2mm radius? No glue

mark?

Check at least 5 pcs with master color

panel Compare color on all

components to match together (color

on drawer, top, leg,…)

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Final Inspection Report Report No:

850 42 nd Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E: Sitcom@sitcomfurniture.net First Refinal 1 Refinal 2

Ins Date: Cust:Sitcom Vendor: Factory: Qty Inspect Ac Re

Qty (PCS) Major Minor

Passe

d Failed 91_280 13 1 2

281_500 20 2 3 501_1200 32 3 4 1201_3200 50 5 6

Approved sample dd: Signed by: Approved color chip dd: Signed by:

F1-Color does not match the color chip D1-Chipped finish/wood(less than 1/8")

W3-Knot split (less than 1 inch) F3-Finish application uneven/inconsistent

W4-Knot split (greater than 1 inch) F4-Bubles dried into finish

W5-MC outside specified range(indoor furniture>12%)

W6-Mold or mildew

W7-Offensive odor F7-Color or gloss level outside approved shade band

F9-Debris dried into finish Others

C1-Drawers not even/level F11-U and V groove not clean/smooth H1-Corrosion

C2-Loose dowels F12-Excess finish on floor contact surface? H2-Damage(ex: bent, scratched, broken)

F13-Blushing (cloudy finish) H3-Install too closed to edge C4-Dovetail joints chipped,cracked, etc F14-Orange peel surface texture H4-Install unevenly

H5-Loose or stripped(included screw)

C8-Glue not as specified(Includes wrong glue type)

C9-Wrong joint type F19-Rough surface texture

C10-Joint failure F20-Permanent finger prints in finish (not removable) Others

C11-Joint gapped

C13-Not square(ex: joints, panels, cases) U1-Open seam O3-Levelers do not function as intended

U2-Skewed or crooked seam, not straight, bowed U3-Skipped stich

C17-Unstable and could result in collapse or injury U5-Hole/tear in fabric

U6-Pile crushed(velvet) P2- Drop test failed

U8-Scratch/abrasion marks A2-Assembled unit stability posing safety issue U9-Soil

A3-Difficult to assemble U10-Exposed staples (no sharp point) P6-Inconsistent packaging(unit to units)

M1-Carton sequencing missing

M4-Master carton label missing M5-SKU# or PO# missing or incorrect.

U17-Missing/incorrect label(ex: law label) U18-Chatter marks on leather M7-Mis-spelling on master carton label

Others

Actual MC range: Assembling Qty:

Overall Comments and Disposition:

Name ( ) Name ( )

3 3

Level 1 (AQL 4.0)

Result

3

Min Assembled Qty required

Cust's PO# Item/Sku# Description

Inspect

ed level:

AQL4.0 L1;

100%, Dup.

Inspect

ed Qty (PCS)

F5-Shading within unit(color or gloss level is inconsistent within single unit)

F15-Overspray (ex: onto hardware or adjacent panel, )

F21-Overwhelming odor not consistent with normal smell

O1-Component doesn't operate smoothly(door, drawer, )

H8-Tools provided do not perform as easy bent or stripped.

intended-D7-Gouge(breaks/penetrates wood fiber)

H N L I N G D M A G E

D3-Ding/dent (finish not broken, diameter 1/8" or less)

D6-Surface scratch that penetrates to subtrate D8-Soil/marks(not removable without using cleaning solution, includes residue from tape)

D4-Ding/dent (finish not broken, diameter greater than 1/8")

D5-Surface scratch that does not penetrate subtrate

F6-Shading among lot(color or gloss level is inconsistent among other units in lot)

A12-AI or care instruction missing language required

Others

A7-blurred or unclear printed assembly

instruction-hard to read

A11-Missing extra hardware but can assemble

A10-Missing hardware(can not assemble)

A9-Missing components

A8-Missing or illegibal assembly Instructions

M6-Price ticket(when required) missing or incorrect

P4-Hardware packet do not have red ribbon indicators

M2-Carton warning(when required by law) missing

P5-Actual packaging not consistent with MTL tested report

C R T O N

M A R K I N G

F I N I S H I N G

C5-Delamination (adge band/veneer separation, etc.)

O5-Unstable to the point it could result in collapse or injury

C18-Bad wood repair(ex: excessive putty/glue,sloppy

wood plug,…)

H A D W A E

F U N T I O N

F18-Resin bleed-through(ex:yellow knot show white finish)

P1-Corner protection inadequate H9- Missing hardware

W1-Hole or material (Not consistent with

specs/approval sample)

W9-Warped(includes bow, twist,crook diamond and

cup with >3mm/meter)

C12-Joint expansion/contraction(ex: raw wood

becomes visible due to wood movement)

C3-Wrong dowel type(too short, too long, not groove,.

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4.2 Defect Classification List

FURNITURE DEFECT CLASSIFICATION LIST

(Rev: Feb 08)

I DETERMINATION OF DEFECTS

Critical Defect (C)

- AQL = 0.0 (1 critical defect = failed audit, regardless of location on item)

- Hazardous or unsafe for consumer use

- Violation of any U.S regulation Items can not be sold due to condition

Major Defect (MJ)

Major Defect is likely to result in failure, or to reduce the functionality of the product for its intended purpose If number of major

defective units found is equal or greater than the allowable limit follow AQL table, the

Major defect will be result in product cannot be sold as First

Major defect will be result in customer reject or returning product Major defects will be included but not limited to the following

Negatively affects appearance, durability, or performance of item

Non-compliance with specification or approval sample

ZONE KEY (corresponds to Defect Location Guide)

Zone A = Visual surface (always in view by user during normal use)

Zone B = Secondary visual surface (occasionally in view or can be touched by user during normal use)

Zone C = Not visual surface (rarely in view by user)

One defect can be major when it's in zone A but it can be minor defect if it appear in Zone B or C Refer to below table for detail

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Location / Zone

Product Category: WOOD FURNITURE

2 DEFECT CLASSIFICATION AND SCORING OF DEFECTS

Defect code A B C

1 WOOD

Hole or material (not consistent with specs/approval sample) W1 MJ MJ MJ

Bad wood repair(ex: excessive putty/glue,sloppy wood plug,…) C18 MJ MJ mn

3 FINISH

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Distressing and overall aesthetic does not match approved

Shading within unit(color or gloss level is inconsistent within

Shading among lot(color or gloss level is inconsistent among

Debris dried into finish (dust, leaves,hair dried into finish) F9 MJ mn 0

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Upholstery construction and padding are not consistent with

Shading within unit(color or gloss level is inconsistent within

Shading among lot(color or gloss level is inconsistent among

5 HANDLING DAMAGE

Ding/dent (finish not broken, diameter greater than 1/8") D4 MJ mn 0

Soil/marks(not removable without using cleaning solution,

6 HARDWARE

Unstable on level surface (i.e wobbly, loose, not structurally

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8 FINAL ASSEMBLY INSPECTION

blurred or unclear printed assembly instruction-hard to read A7 mn mn mn

9 PACKAGING

Hardware packet do not have red ribbon indicators(when

10.CARTON MARKING

4.3 Defect location guide

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DEFECT LOCATION GUIDE

FURNITURE Rev: Feb 08

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C zones indicated on Sitcom Furniture Defect Classification List.

2.

always in view by user during normal use.

occasionally in view by user during normal

use.

in view by user during normal use.

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Case Goods

Zone A

Zone A: all visible

areas of front view

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Zone A: outside surfaces of legs

Zone A

Zone C: Bottom

sides of case goods

Zone B: Entire perimeter of turned legs less than 6”

height

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Zone C: Interior of

drawer case goods

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Zone A: bottom of removable shelf.

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Dining Table

Zone A:

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Zone B: bar underside of table top and hidden by table top.

Zone C:

underneath of table top

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Zone C: underneath of leg

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Zone A:

Back rest, seat,

apron, front leg face

Zone B:

Inner side of leg.

Zone A

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Zone C: underside of seat and leg

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Zone C:

Slat.

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Zone B:

back of HB

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